Hybrid insulated concrete form and method of making and using same

Abstract

The invention comprises a product. The product comprises a foam insulating panel having a first primary surface and an opposite second primary surface. A removable concrete form is spaced from the foam insulating panel and a concrete receiving space is defined between the second primary surface of the foam insulating panel and the removable concrete form. A method of using a hybrid insulated concrete form is also disclosed.

1 - 17 . (canceled) 
     
     
         18 . A method comprising:
 providing a removable concrete form panel;   providing a foam insulating panel spaced from the removable concrete form panel defining a concrete receiving space therebetween wherein the foam insulating panel has a first primary surface and an opposite second primary surface;   providing a plurality of anchor members extending through the foam insulating panel and extending outwardly from the first primary surface into the concrete receiving space, whereby an end of each of the plurality of anchor members is disposed between the foam insulating panel and the removable concrete form panel;   providing an elongate panel bracing member supporting the foam insulating panel;   placing a quantity of plastic concrete in the concrete receiving space;   allowing the plastic concrete in the concrete receiving space to at least partially cure; and   removing the removable concrete form from the at least partially cured concrete.   
     
     
         19 . The method of  claim 18  further comprising providing an elongate hollow sleeve disposed between the removable concrete form panel and the foam insulating panel. 
     
     
         20 . The method of  claim 19  further comprising:
 inserting a first rod through the foam insulating panel and into the elongate hollow sleeve; and 
 inserting a second rod through the removable concrete form panel and into the elongate hollow sleeve. 
 
     
     
         21 . The method of  claim 20  further comprising attaching an end of the first rod to the elongate panel bracing member. 
     
     
         22 . The method of  claim 21  further comprising attaching an end of the second rod to a frame member associated with the removable concrete form panel. 
     
     
         23 . The method of  claim 18 , wherein each of the plurality of anchor members has a first end and an opposite second end and wherein a flange is disposed adjacent the first end and extends radially outwardly therefrom and wherein the flange contacts the second primary surface of the foam insulating panel. 
     
     
         24 . The method of  claim 23 , wherein each of the plurality of anchor members has an enlarged portion adjacent the second end disposed between the foam insulating panel and the removable concrete form panel. 
     
     
         25 . The method of  claim 23  further comprising a layer of reinforcing material on the second primary surface of the foam insulating panel whereby at least a portion of the layer of reinforcing material is captured between the flange of each of the plurality of anchor members and the second primary surface of the foam insulating panel. 
     
     
         26 . The method of  claim 25 , wherein the layer of reinforcing material is a discontinuous material. 
     
     
         27 . The method of  claim 25 , wherein the layer of reinforcing material is a fabric, a mesh or a web. 
     
     
         28 . The method of  claim 27 , wherein the fabric, mesh or web is made from polymer fibers, fiberglass, basalt fibers, aramid fibers, or carbon fibers. 
     
     
         29 . The method of  claim 25 , wherein the layer of reinforcing material is a fiberglass mesh. 
     
     
         30 . The method of  claim 18 , wherein the removable concrete form panel is a removable insulated concrete form panel. 
     
     
         31 . The method of  claim 18 , wherein the removable concrete form panel is a removable electrically heated concrete form panel and the method further comprises heating the removable electrically heated concrete form panel. 
     
     
         32 . The method of  claim 18 , wherein the removable concrete form panel comprises:
 a face panel having a first primary surface for contacting plastic concrete and a second primary surface opposite the first primary surface, wherein the face panel is made from a heat conducting material; and   an electric heating element in thermal contact with the second primary surface of the face panel.   
     
     
         33 . The method of  claim 18 , wherein the foam insulating panel has an R-value of greater than 4. 
     
     
         34 . The method of  claim 32 , wherein the removable insulated concrete form panel has an R-value of greater than 4. 
     
     
         35 . The method of  claim 30 , wherein the removable insulated concrete form panel has an R-value of greater than 4 and the foam insulating panel has an R-value of greater than 4. 
     
     
         36 . The method of  claim 30 , wherein the removable insulated concrete form panel has an R-value of greater than 4 and the foam insulating panel has an R-value of greater than 8.